Konica IP421 Service Manual v1e

IP-421

SERVICE HANDBOOK

July, 2000

Ver. 1.0

KONICA CORPORATION

TECHNOLOGY SUPPORT CENTER

TOKYO JAPAN

KCSI42110

MF13JA1780

Safety and Important Warning Items

SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the Safety and Important Warning Items described below to understand them before doing service work.

IMPORTANT NOTICE

Because of possible hazards to an inexperienced person servicing this equipment, as well as the risk of damage to the equipment, Konica Corporation, strongly recommends that all servicing be performed only by Konica-trained service technicians.

Changes may have been made to this equipment to improve its performance after this service handbook was printed. Accordingly, Konica Corporation, makes no representations or warranties, either expressed or implied, that the information contained in this service handbook is complete or accurate. It is under-stood that the user of this service handbook must assume all risks or personal injury and/or damage to the equipment while servicing the equipment for which this service handbook is intended.

Therefore, this Service Handbook must be read carefully before doing service work both in the course of the technical training and even after that, for keeping the correct maintenance and control of the copying machine. Keep the Service Handbook also for the future service. When it is impossible to read the description about safety and warning (due to contamination or tear), the relevant page should be re-placed.

DESCRIPTION ITEMS FOR Danger, Warning AND Caution

In this Service Handbook, each of three expressions, “ Danger, Warning and Caution” is defined as follows together with a symbol mark to be used in a limited meaning.

When servicing, the relevant works (disassembling, assembling, adjustment, repair and maintenance) need to be conducted with utmost care.

Danger: Actions having a high possibility of suffering death or serious

wound

Warning: Actions having a possibility of suffering death or serious wound

Caution: Actions having a possibility of suffering a slight wound, medium

trouble and material damage

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Safety and Important Warning Items

SAFETY WARNINGS

● MODIFICATIONS NOT AUTHORIZED BY Konica

Konica copiers are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network.

Photocopier design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degrading performance and safety. Such modifications are therefore strictly prohibited. The points listed below are not exhaustive, but they illustrate the reasoning behind this policy.

Prohibited Actions :

(1) Using extension cables or a different power cord than specified by Konica.

(2) Using other fuses than specified by Konica. Safety will not be assured, lead-

ing to a risk of fire and injury.

(3) Disabling fuses or bridging fuse terminals with wire, metal clips, solder or

similar. (This applies also to thermal fuses.)

(4) Removing air filters (except for replacement).

(5) Disabling relay functions (such as wedging paper between relay contacts,

etc.).

(6) Disabling safety functions (interlocks, safety circuits, etc.). Safety will not be

assured, leading to a risk of fire and injury.

(7) Performing actions to copier not described in the instruction manual or the

service handbook.

(8) Using parts other than specified by Konica.

● CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Konica copiers are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engineer from the risk of injury. However, in daily use, any electrical equipment will be subject to parts wear and eventual failure. In order to maintain safety and reliability, the customer engineer must perform regular safety checks.

Caution :

(1) Wear clothing that facilitates work and is designed for safety.

(2) Carry out all procedures carefully to prevent injury.

(3) Be sure to disconnect the power cord of the copier and all optional equip-

ment from the AC outlet.

Simply turning off the power switch is not sufficient, because paper feed units or other electrical equipment may be powered also when the power switch is turned off.

(4) Proceed with special care when performing operation checks or adjustment

while the unit is powered. When carrying out operation checks or adjustment while external covers are removed, the risk of electrical shock exists when touching parts which carry high voltage or electrical charge. The risk of injury exists when touching moving parts such as gears or chains.

C-2 IP-421 PRINT CONTROLLER

Safety and Important Warning Items

The following list is not exhaustive, but it includes actions which must be carried out at every service call.

Caution :

(1) Check external covers and the frame for sharp edges, burrs, or nicks. (2) Check external covers and hinges for loosening or damage. (3) Check wiring for squeezing or damage. (4) Check power cord for insulation problems (conductor must not be exposed). (5) Check that power cord is properly connected.

Warning :

(1) Verify that the copier is properly grounded. If a problem is detected, estab-

lish a proper ground connection.

(2) Connecting the ground lead to an improper point such as listed below re-

sults in a risk of explosion and electric shock. Unsuitable ground points:

- Gas pipe

- Lightning rod

- Telephone line ground

- Plastic water pipe or water pipe or faucet that has not been approved by authorities for grounding use

● PRECAUTIONS FOR ON-SITE SERVICE

Caution :

(1) Before performing maintenance work, read all relevant documentation (ser-

vice handbook, technical notices, etc.) and proceed according to the prescribed procedure, using only the prescribed tools. Do not carry out any adjustments not described in the documentation.

(2) If the power cord is damaged, replace it only with the specified power cord.

If the power cord insulation has been damaged and there are exposed sections, shortcircuits and overheating may occur, leading to a serious fire risk.

(3) Do not route the power cord so that it can be stepped on or pinched. Other-

wise overheating may occur, leading to a serious fire risk.

(4) When disconnecting any cables, always grasp the connector and not the

cable (especially in the case of AC and high-voltage leads). (5) Carefully remove all toner remnants from electrical parts, electrodes, etc. (6) Make sure that wiring cannot come into contact with sharp edges, burrs, or

other pointed parts. (7) Double-check to make sure that all screws, components, wiring, connec-

tors, etc. that were removed for maintenance have been reinstalled in the

original location. (Pay special attention to forgotten connectors, pinched

cables, forgotten screws, etc.) (8) When installation and preventive maintenance, verify that the power cord

has been securely plugged into the AC outlet. Contact problems may lead

to increased resistance, overheating, and the risk of fire.

Warning :

(1) Before disassembling or adjusting the optical unit or any parts that use a

laser, make sure that the power cord has been disconnected.

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Safety and Important Warning Items

(2) Do not remove the main cover of the write unit. Direct exposure of the eye to

laser beams may lead to blindness. (3) Do not turn the copier on while the write unit is not installed in its normal

position. (4) Danger of explosion if battery is incorrectly replaced, replace only with the

same or equivalent recommended by the manufacturer. Discard used bat-

teries according to the manufacture’s instructions.

Vorsicht :

(4) Expiosionsgefahr dei unsachegemäßem Austausch der Battetie. Ersatz nur

durch denselben oder einen vom. Hersteller empfohlenen gleichwertigen Typ.

Entsorgung gebrauchter Batterien nach Angaben des Herstellers.

● HANDLING OF MATERIALS FOR SERVICING

Caution: Drum cleaner (alcohol-based) and roller cleaner (acetone- based) are

highly flammable and must be handled with care.

When using these materials for cleaning of copier parts, observe the

following pre-cautions.

(1) Disconnect the power cord from the AC outlet. (2) Use only a small amount of cleaner at a time and take care not to spill any

liquid. If this happens, immediately wipe it off. (3) Perform cleaning only in an environment where sufficient ventilation is assured.

Breathing large quantities of organic solvents can lead to discomfort. (4) Do not replace the cover or turn the unit on before any solvent remnants on

the cleaned parts have fullyevaporated.

Caution: Toner and developer are not harmful sub-stances, but care must be

taken not to breathe excessive amounts or let the substances come

into contact with eyes etc.

If this happens, immediately rinse with eye wash and plenty of water,

and consult a physician.

● MEASURES TO TAKE IN CASE OF AN ACCIDENT

(1) If an accident has occurred, the distributor who has been notified first must

immediately take emergency measures to provide relief to affected persons

and to prevent further damage. (2) If a report of a serious accident has been received from a customer, an on-

site evaluation must be carried out quickly and Konica Corporation must be

notified. (3) To determine the cause of the accident, conditions and materials must be

recorded through direct on-site checks, in accordance with instructions is-

sued by Konica Corporation.

● CONCLUSION

Safety of users and customer engineers has topmost priority, ranking even higher than operability. Safety depends on a appropriate maintenance work and is maintained by proper daily service work conducted by customer engineers. When performing service, each copier on the site must be tested for safety. The customer engineer must verify the safety of parts and ensure appropriate management of the equipment.

C-4 IP-421 PRINT CONTROLLER

Contents

CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS ............................................ C-1

1. Overview

■ Product specifications ................................................................................ 1-1

● IP-421 print controller ..................................................................................................... 1-1

■ Product overview ........................................................................................ 1-3

● Capabilities of the IP-421 ................................................................................................ 1-3

● Startup sequence of the 7020 series + IP-421 system ................................................... 1-4

● Data processing of the IP-421 (See data flow) ............................................................... 1-4

● Data flow ......................................................................................................................... 1-5

■ Option ......................................................................................................... 1-6

● KN-303 Network card ..................................................................................................... 1-6

● Hard Disk (HD-103) ........................................................................................................ 1-6

● Post Script 3 (PS-341) .................................................................................................... 1-6

2. Disassembly/Assembly

■ Construction ............................................................................................... 2-1

■ Disassembly / Assembly procedures.......................................................... 2-2

● Removal/Installation of boards........................................................................................ 2-2

● Expanding the memory (MU-403/MU-404/MU-405) ....................................................... 2-5

● Installation / Removal of HD-103 .................................................................................... 2-7

● Installation / Removal of PostScript 3 option (PS-341) ................................................... 2-9

3. Troubleshooting

■ Troubleshooting .......................................................................................... 3-1

● Troubleshooting of the IP-421 and copier ....................................................................... 3-1

4. Appendices

■ Upgrading the Firmware ............................................................................. 4-1

● Rewriting the Flash ROM ................................................................................................ 4-1

● In case of failure in rewriting the firmware ...................................................................... 4-2

● Replacing ROM .............................................................................................................. 4-3

■ Functions of parts mounted on boards ....................................................... 4-4

● Connector ....................................................................................................................... 4-5

● Switch ............................................................................................................................. 4-5

● Jumpers .......................................................................................................................... 4-5

● Individual ICs’ functions .................................................................................................. 4-5

INDEX ..................................................................................................... Index-1

C-5 IP-421 PRINT CONTROLLER

Overview

■ Product specifications

● IP-421 print controller

Type: Built in Konica 7020 series copy machine

Paper size: A3, A4, A5, B4, B5, B6, 11"X17", 8.5"x14", 8.5"x11", 5.5"x8.5"

Paper feeding: Same as copier

Output stack capacity: Same as copier

Mode: Possible dual mode of copy machine/printer (up to 5 jobs)

Next job reservation: Next copy job can be reserved during print job.

Special printing features: Printing on both faces, choice of paper type, zoom

Chapter 1 Overview

function, choice of paper tray, choice of output tray, choice of print quality, Alternate function, sort/ group function, staple function, layout function, front/back cover intersheet function, booklet function, smoothing function, page protection function, watermark function

Direction of printing: portrait, landscape

Resolution: 600 dpi

Scan Resolution: 600 dpi/400 dpi/300 dpi/200 dpi

Gradation: 2

Number of output pages: 1-999

Warm-up: Same as copier

CPU: Pentium MMX-166Mhz

Memory: 32MB (standard), expandable up to 160MB (option:MU-403 / MU-

404 / MU-405)

Cards: Controller board x1

PCI relay board x1

KN-303 Network card (option)

Option:Harddisk Drive (HD-103)

PS option (PS-341)

1-1 IP-421 PRINT CONTROLLER

Chapter 1 Overview

Interface: Parallel port

Based on Centronics (IEEE 1284)/Amphenol male 36pin connector

Network interface: (option)

KN-303 Network card

Network: Ethernet (100BaseTX/10BaseT)

Protocols: IPX/SPX (NetWare),

TCP/IP (LPD/LPR, peer-to-peer)

AppleTalk (EtherTalk)

Compliant OS:

Windows 95/98

Windows NT4.0/2000

Macintosh

Unix

Printer Language:

PCL

PostScript3 (option)

Printer drivers:

Windows 95/98 printer driver

Windows NT4.0/2000 printer driver

Host computer: A Windows based computer

Macintosh

Unix

Finisher: FS-107

paper tray unit: DB-209,DB-409

Size: 240 mm(W) x 160 mm(H) x 37 mm(D)

Weight: Approx. 1.1 kg

Power source: 5 V, 2 A or less (supplied from copier)

Operating conditions:temperature: 10-30˚C,

humidity: 20-80%RH (condensation not allowed)

Restrictive Conditions:

1-2 IP-421 PRINT CONTROLLER

• In the Printer mode, the EKC (Electric Key Counter) of the Konica 7020 series is not available.

• Although the Weekly Timer function of the Konica 7020 series is available in the Printer mode, the power is not turned Off until the data output is finished when print data remains in the E-RDH.

Notice: Specifications are subject to change for improvements without no-

tice.

Chapter 1 Overview

■ Product overview

● Capabilities of the IP-421

The Konica IP-421 print controller allows you to use the Konica 7020 series copying machine as a printer connected to computers and a network. It receives print jobs from computers and network and converts them into image data (video data) that the Konica 7020 series copying machine prints out.

The IP-421 print controller is characterized as follows.

• Built in the Konica 7020 series copying machine.

• The drivers interfacing with Windows 95/98 and NT4.0/2000 allow use of the

functions of the Konica 7020 series copying machine.

• The KN-303 Network card allows use of the IP-421 as a network printer.

• A system can be upgraded by the renewal of the flash memory.

This Service Handbook describes hardware construction, disassembly and assembly procedures, troubleshooting, and appendixes (upgrading firmware, error messages, etc).

IP-421

KN-303

(OPTION)

1-3 IP-421 PRINT CONTROLLER

+ 24 hidden pages